Method of casting and mold



April za, 1925. V1,535,194

E. H. WILLIAMS METHOD 0F CASTING AND MOLD Filed April 21. 192.14

@WMI/wmf l. 4 /M/Clttowug Patented Apr. 28, 1925.

UNITED Ns'rATiszs 1,535,194 PATENT' OFFICE.

EDWARD H. WILLAMS, OF SHARON. PENNSYLVANIA, ASSIGNOR TO VALLEY MOULD AND IRON CORPORATION, OF SHARPESVILLE, PENNSYLVANIA, A CORPORATION OF NEW YORK.

METHOD OF CASTING AND MOLD.

Application led April 21, 1921.

To all iol/.0m t may concern Be it known that I, EDWARD H. VILLIAMS, a citizen of the United States, residing at Sharon, in the county of Mercer, State of Pennsylvania, have invented certain new and useful Improvements in Methods of Casting and Mold7 of which the following is a specification.

This invention relates broadly to metallurgy and more specially to a mold and method of casting steel ingots.

The principal object of the present invention is the method of cast-ing steel ingots in a horizontal closed chill mold and with the axis of the top surface of the matrix inclined to the horizontal. within predetern'iined limits.

An equally important object of the presA ent-invention is an ingot mold provided with an outside runner and with leads from said runner tothe matrix of the mold whereby the gate may be broken from the ingot when the mold is ready to be stripped.

Another and more specifi-c object of the present invention is the method of casting` horizontal ingots and wherein the inclination of the top surface of the matrix of the mold is between the limits of one Vdegree and len degrees inclination to the horizontal.

Ano-ther and further object of the present invention an ingot mold for casting horizontal ingrots and the like and wherein one end of the mold provided with a channel to receive a runner tile and with openings leading from the channel to the matrix of the mold whereby suitable clay or the like inlets may extend from the runner tile to the matrix, whereby the runner tile and conduit may be broken away and the steel gate broken olf before the ing'ot is stripped from the mold.

Another object of the present invention is a mold for castinghorizoiital ing-ots and the like and wherein substantially the entire surface of the nioldmatrix comprises chilled metal walls and with n'ieans being` provided to supply molten steel to the matrix through one end wall of the mold.

A still further object ot' the present invention is a mold for casting` horizontal ingots which mold is provided with an open channel adjacent one end thereof adapted to ie ceive a runner tile in such manner that the side walls of the runner tile are supported by said channel, and wherein a removable Serial No. 463,230.

plate is arranged to cover said channel and retain said runner tile in position.

Other and further objects of this, invention will in part be obvious and will in part be pointed out hereinafter in the specification following by reference to the accompanyingY drawings forming a part hereof.

Realizing that the present invention may he embodied in constructions other than those specifically herein disclosed, it is desired that the disclosure herewith shall be considered as illustrative and not in the limitingl sense.

Figure l is a plan view of one form of mold carrying out the present invention:

Figure 2 is a sectional view taken on line :2-2 Figure l;

Figure 3 is a sectional view taken on line of Figure l.

Heretofore in the art it has been proposed to cast steel ingots in horizontal molds in order to avoid segregation and to form an ingot all of which could be rolled into finished product. In the present invention the inclination of the mold to the horizontal is predetermined in order to prevent entrapping gases in the top of the mold'matrix7 and in order t-o cause slag or any foreign matter, such as loam or chunks of sand, to be placed where desired in the ingot when cast instead of permitting the substances to lodge by chance anywhere inthe longitudinal upper surface of the ingot. There the placing of these deleterious substances, when they occur, is controlled it is possible to remove the flaw from the ingot without effecting lout a very small part of the .ingot body. There the inclination of the top surface of the matrix of the mold is too slight7 gas is liable to be entrapped in the top portion of the molten metal and consequently leave a bad upper surface on the ingot. Also there is a possibilityv of the slag` accumula-ting in a spot on the top of the ingot along one side thereof, and this likewise might leave a. rough spot or bad place in the ingot whichrwould greatly interfere with rolling or hammering of the ingot into finished product. Therefore, there is an angular limit below which the inclination of the top of the matrix cannot safely go. As the inclination is increased a condition is reached which also measures the maximum limit of inclination. there the upper surface isv in clined beyond this maximum limit the tendency is to invite segregation; to produce piping in the uppei corner of the ingot; and to produce a condition wherein spongy metal and a bad surface is encountered in the upper corner ot the ingot. It will be obvious that if the inclination were continued the linal result would be a vertical mold which would cast the vertical ingot together with all the ditliculties which attend casing ingots vertically, and which are overcome bymy improved method ot lioriff zontal casting. A large number ot experiments have determined that the minimum limit to the inclination o't' the upper wall ot the matrix oi the ingot mold is approximately one (l) degree and the maximum limit is approximately ten (10) degrees from the horizontal. It therefore follows that the best results in casting horizontal steel ingots are obtained by inclining the upper surface o'f the matrix wall between the minimum limit of one degree and the maximum limit ot' ten degrees. The inclination runs towards the outlet :trein the mold and preferably this gas outlet is located ad- `iacent the inlet of molten steel to the mold, in 'tact in practice the gas outlet may comprise space between the ruimer and the mold side wall.

lt has also been proposed in the casting' of steel ingots heretofore to provide ruimer tiles which would set in the body ot the mold in such manner that a portion oi' the runner tile becomes a part ot the matrix wall. In the use ot' gaseous or non-piping steel to cast the ingot it is desirable that the entire mass of steel in the mold matrix be chilled on all surfaces as quickly as possible after the mold is filled and where the runner tile touches the molten steel this particular portion o the steel does not chill as quickly as the portion in contact with the chill metal walls oit' the mold. Furthermore, where the runner tiles are set in an opening through the mold wall and are enclosed between the ingot and the inold7 diiiieulty is encountered in breaking the gate ot steel which forms in the runner tile when the iiigot cools since the gate is within the mold and cannot be readily reached Yfrom the outside. lt is necessary that this stein or gate be broken olil before the moldccan be stripped from the ingot.

To obviate these ditliculties I have provided a construction wherein the runner tile while being supported by the mold body is in eii'ect outside ot' the moldv` that is` it is so constructed that the entire runner title may be reached from outside the mold and may be broken away and removed from the mold. The runner is so arranged as to be completely supported while in position and to have removable supports provided so that when the runner is broken the gate may be easily pried or broken away after the metal has cooled so that the mold may be easily stripped from the ingot.

Referring to the drawings it is to be understood that the particular torni et mold exemplities but one of the many iorms in which the present invention may be einbodied. 'l`he body portion 1 is provided with a suitable matrix 2, and one end il oi the wall is inclined so that that end of the body portion may be raised by inserting a suitable crane hook or the like in the staple 5 as will later be explained. rfhe runner tile end (S o't the mold body is preferably straight and is provided with an upper recess openingl 7 and a lower recess opening S. The end wall ot the body is provided with a channel 9 which is adapted to receive a runner tile lO o'lf lire clay or the like. Staples ll and 12 are provided on the end of the mold body and are adapted to receive a bar 11 which torins an abutment tor the wedges 15 that press a suitable plate 16 against the runner tile 10 and thereby support the runner tile in position at the end ot the mold body. The runner tile is provided with a substantially vertical opening 17 from which lead outlet openings 18 and 1f). These outlety openings preferably are ot different sizes in order that substantially equal volumes ot' steel will issue trom both openings during the pouring operation. Since the lower openingl is under a greater terro static head than the upper opening. the lower openingr may be a slightly lesser area in cross section than the upper opening. The recesses T and f5 in the mold body adjacent the runner channel are adapted to be iilled with suitable material either 'tire clay, loam` or tire brick. which is provided with conduits 20 and 2l that connect with and 't'orm continuations ol! the openings 1S and l). Preferably the upper member carrying the conduit 20 is arranged to be slightly shorter than the recess 7 so that a gas outlet opening is provided adiacent the upper end ot the mold. A suitable t'ountain 2li is placed over the runner tile and is adapted to lead the molten steel into a substantially vertical conduit 17. rl `he mold as illustrated in the drawings has a matrix top surtace which is substantially parallel to the bottom side edges ot the mold. This mold therefore is adapted to be on a stool Q53 which mav be inclined by means ot supports 2G and 2.7 and the stool may have a ledge 2S on the lower edge in order to prevent any sliding olf the mold on the stool. The supports Q6 and 2T arc so constructed as to produce. an inclination to the upper top surface ot the matrix ot' thc mold which inclination is `greater than one (l) degree and less than ten (10) degrees. An ideal inclination is one near the lower limit of inclination and yet sulliciently great, so that all gases are caused to escape through the gas outlet during the pouring lope ation and wherein any foreign material in the steel is caused to rise into that portion of the ingot adjacent the upper connecting gate or stem which is formed in the conduit 20, so that such foreign material will be carried away when the gates are broken from the ingot. It is preferred, where plural inlet openings are utilized as illustrated in the drawings, that the upper opening shall be directly over the lower opening and that the upper opening shall be as high as the upper limits of the matrix top wall so that deleterious material will tend to fioat into the conduit and also so that the steel flowing' from the upper conduit will flow directly upon the steel flowing from the lower conduit and cause a vertical mixing action which will prevent any segregation during 'the pouring operation. My invention, however, is not limited to a tile having a plurality of inlet openings since the invention may be carried out with a single inlet. Then the steel in the mold has solidified and the ingot is sufficiently cool for stripping, the runner column and ruimer conduits may be broken away. This leaves the gate clear where it may be broken ott'. However. the gate breaking operation may be carried out by inserting a crane hook in the staple and raising that end of the mold, using the other end as a pivot. rlhe weight of the ingot will cause the ingot to remain on the stool while the mold end rises and thus the mold becomes a pry which breaks the gate from the ingot. Then crane hooks may be inserted in the staples ll and l2 and the mold may be lifted free of the ingot and reset where desired.

rlhe present invention is illustrated as a single mold unit. It will be noted that the construction is particularly adapted for use' with a plurality of mold units stacked one over the other so that lthe runner tiles conneet one with another and gas outlets of a lower mold opens directly into the matrix of the next mold above and the top of one mold becomes the stool for the next mold above. lVhen these molds are arranged in vertical stacks the runner columns extend, as units, through the whole stack and the opening of an upper tile connects with the opening in the next lower tile and so on tl'iroughout the series, with the fountain over the top tile.

From the t'oregoing disclosure it will ap` pear that the present invention provides a method for casting and also an ingot mold wherein all `sides of the ingot are adaptedto be chilled and wherein the gate or stem may be easily broken from the ingot when the ingot is cool.

Having thus described my invention, what lclaim is:

l. The method of casting steel ingots in Vhorizontal molds which comprises providing a chill for the upper surface of the mold matrix, arranging a gas outlet in the highest part of the matrix,and inclining the upper surface of the mold matrix Vto the horizontal and toward the gas outlet with the lower limit of inclination being substantially one degree from the horizontal, and introducing the molten steel into one end of the matrix.

Themethod of casting steel ingots in horizontal molds which comprises providing a chill for the upper surface of the mold matrix, arranging a gas outlet in the highest part of the matrix, and inclining the upper surface of the mold matrix to the horizontal and toward the gas outlet with the lower limit of inclination being substantially one degree from the horizontal.

The method of casting steel ing-ots in horizontal chill covered molds which comprises inclining the upper portion of the mold matrix to the horizontal with the lower limit of inclination being substantial-ly one degree from the horizontal, and introducing the molten steel into one end of the matrix.

a. The method of casting steel ingots or the like which comprises casting the ingots in a horizontal closed chill mold body provided with a gas outlet and mounted on a suitable stool, and wherein the upper portion of the mold matrix is inclinedv to the horizontal and toward the outlet with the maximum inclination being substantially ten degrees, and introducing the steel adliacent the gas outlet.

The method of casting steel ingots or the like which comprises casting the ingots in a horizontal covered chill mold body provided with a outlet and mounted on a suit-able stool, and wherein the upper portion of the mold matrix is inclined to the horizontal and toward the gas outlet with the maximum inclination being substantially ten degrees.

(i. The method of casting steel ingots in horizontal molds provided with a gas outlet and mounted on a suitable stool wherein the upper surface of the mold matrix is a chill surface and is inclined toward the gas outlet and to the horizontal between the limits of inclination of one degree mininunn to ten degrees maximum introducing the steel rapidly into the mold and chilling the steel in the mold as quickly as possible.

7. The method of casting steel ingots in horizontal molds provided with a gas outlet and mounted on a suitable stool wherein the upper surface of the 4mold matrix is inclined toward the gas outlet and to the horizontal between the limits ot' inclination of one degree minimum to ten degrees maximum.

8. The method of casting steel ingots in closed chill molds mounted on suitable stools wherein the upper surface of the mold matrix is inclined to the horizontal between lll) IIS

lIO

the limits of inclination of one degree minimum to ten degrees maximum introducing the steel rapidly into the mold and chilling,l the steel in the mold as quickly as possible.

9. The method of casting steel ingots in full covered full chill molds mounted on suitable stool wherein the upper surface of the mold matrix is inclined to the horizontal between the limits of inclination of one degree minimum to ten degrees maximum.

10. An article of manufacture a mold. for casting horizontal steel ingots and comprising` a trough-like body portion, one end of said body portion being formed in such i'nanner that said end will clear an ingot cast in the mold when the said end is lifted about the opposite end of the mold as a pivot, and wherein the runner end of said mold is provided with an open channel adapted to receive a suitable runner tile.

ll. An article of manufacture a mold for casting horizontal steel ingots and comprising a trough-like body portion. one end of said body portion being formed in such manner that said end will clear an ingot cast in the mold when the said end is lifted about the opposite end of the mold as a pivot, and wherein the runner end of said mold is provided with an open channel at substantially right angles to the axis of the matrix of the mold and adapted to receive a .suitable runner tile.

l2. An article of manufacture a` mold for casting horizontal steel ingots and comprising a trough-like body portion. one end of said body portion being formed in such a manner that said end will clear an ingot cast in the mold when the said end is lifted about the opposite end of the mold as a pivot. and wherein the runner end of said mold is provided with an open channel adapted to receive a suitable ruimer tile said body portion having an opening` leading` from said channel to the matrix of the mold.

l-l. An article of manufacture a mold for casting horizontal steel ingots and comprising a trough-like body portion. and wherein the runner end of the said mold is provided with an open channel adapted to receive a suitable runner tile.

lel. An article of manufacture a mold for casting horizontal steel ingots and comprising a trough-like body portion. and wherein the runner end of said mold is provided with an open channel at substantially right angles` to the axis of the matrix of the mold and adapted to receive a suitable runner tile said body portion having` an openirm` or openings leading from said channel tok the matrix of the mold.

l5. mold for 'asting horizontal steel ingots coninrising an inverted trough-like body portion having heavy chill body walls adapted to quickly absorb heat of molten steel within the mold matrix. said body having an opening adjacent one end of the matrix portion and adapted to receive a runner conduit, in combination with a runner tile. adapted to lit said opening.

16. A mold for casting;- horizontal steel ingots comprising an inverted trough-like body portion having` heavy chill body walls adapted to quickly absorb heat of molten steel within the mold matrix7 said body having an opening` adjacent one end of the matrix portion and adapted to receive a runner conduit in c-on'ibination with a runner tile adapted to lit said opening` and means to retain said tile in said opening.

1T. Ar mold for casting horizontal steel ingots comprising an inverted trough-like body portion having heavy chill body walls adapted to quickly absorb heat of molten steel within the mold matrix, said body having an opening adjacent one end of the matrix portion and adapted to receive a runner conduit. in combination with a runner tile adapted to lit said opening7 means to retain said tile in said opening. and a gas outlet adjacent said runner tile.

18. An article of manufacture comprising a mold for horizontal ingots. said mold bcing provided with heavy metal side walls to absorb heat quickly from molten steel within said mold. one end of said mold being provided with an opening adapted to receive a conduit. an open channel across said opening and adapted to receive and support a suitable runner tile. and means to retain a runner tiley within said channel.

lf). An article of manufacture comprising a mold for horizontal ingots. said mold being provided with heavy metal side walls to absorb heat quickly from all sides of molten steel within said mold` one end of said niold being` provided with an opening adapted to receive a conduit. an open channel across said opening and adapted to receive and support a suitable ruimer tile, and means comprising a wedge retained plate to support a runner tile within said channel.

Q0. iis an article of n'ianufacture a mold for horizontal ingots` said mold being provided with heavy metal side walls to absorb heat quickly from molten steel within said mold. one end of said mold being provided with an opening adapted to receive a conduit. an open channel across said opening and adapted to receive and support a suitable runner tile. a bar ren'iovably mounted on the end of the mold. a plate over the runner tile. and means between the bar and plate to hold the parts in position.

2l. s an article of manufacture a mold for horizmital ingols. said mold comprising an inverted trough provided with heavy metal side walls to absorb heat quickly from molten steel within said mold. one end of the mold being inclined upwardly and inwardly the other end of said mold being provided with an opening adapted to receive a conduit, an open channel across said opening and adapted to receive and support a suitable runner tile, a bar removably mounted on the end of the mold, a plate over the runner tile, and means between the bar and plate to hold the parts in position.

22. An article of manufacture a mold for casting horizontal steel ingots and comprising` a trough-like body portion, wherein the runner end of the said mold is provided with an open channel adapted to receive a suitable runner tile, a runner tile in the' channel, and removable means to enclose and support said ruimer tile.

23. An article of manufacture a mold for casting horizontal steel ingots and comprising a trough-like body portion, wherein the runner end of the said mold is provided with an open channel adapted to receive a suitable runner tile, a runner tile in the channel. and removable means to enclose and support said runner tile. said means comprising a supporting` plate over the runner tile, and Wedge means to hold the plate in position.

24e. A horizontal ing'ot mold comprising an inverted trough-like body set on a stool, one end of the body being' shaped to clear the ingot cast in the matrix When said end is lifted about the other endvas a pivot, an open vertical channel formed in said other end outside the mold. and a stool to receive a runner tile.

25. The combination of a mold for castingl ingots and comprising an inverted troughshaped body portion with heat absorbing` Walls, said body portion being provided at one end with a runner receiving` opening. a heat absorbing closure for the bottom of the body portion, and means movably mounted With respectto said body portion for closing' one side of the said opening'.

EDVARD H. VILLIAMS. 

